PrimeComposite Flooring System · Project Overview • Daimler India Commercial Vehicles Pvt. Ltd....

PrimeComposite Flooring System

Jointless, Crackfree, Superflat Floors

Case Study: Daimler India Commercial Vehicles Pvt. Ltd.

Contents

PrimeComposite Flooring System – Overview

Case Study – Overview

Method of Execution

Final Product – Outright Success!

Total Lifecycle Cost of Ownership and Savings

Performance Guarantee

Primekss Group – Leaders in Industrial and Warehouse Flooring in Europe

Primekss is the leading industrial flooring contractor in Scandinavia

Presence:

‒ Direct presence in 14 locations in Europe

‒ Presence through Licensed Contractors in 10 more locations world-wide

Patented process for design, construction, and quality control systems

Joint-less on days placement

More than 4 million square meters of reference in place (first one in 2002)

Primekss Rabine 2013.mov

PrimeComposite System – Jointless, Crack-less, Super Flat Floors

• Jointless (no saw-cut joints, no VDC ) concrete floor upto 2000 SqM

• Non-shrink concrete, achieved through proprietary Primekss admixtures and highly sophisticated concrete mix design.

• Execution process managed through electronic PrimeQualitymanagement system.

• Proprietary Primekss admixtures for anti-shrinkage and plasticizer

• Proprietary Primekss HE75/50 Grade Steel fiber reinforcement or equivalent.

• Dry shake hardeners for abrasion resistance

• Day Joints will be pre-engineered HCJ Cosinus Slide or similar

• Floor finishing with state-of-the-art S15R laser boom screed machine (Somero Inc, USA)

• Floating with state-of-the-art heavy duty ride-on-trowels, bull float, etc.

• Dosing steel fibers using high speed imported fiber blower machine

• Dosing admixtures using specialized dispensers and pumps

Design & Engineering

Materials

Plant & Machinery

Executed and Driven by PRIMEKSS LABS

Supply of admixtures by PRIMEKSS

FACTORY

All equipment owned by Primekss Licensee

(ACT in India)

Supply of fibers, joints and hardeners by select world-class

vendors

Key Advantages Delivered

Jointless upto 2000 SqM

• Complete elimination of saw-cut joints

• Complete elimination of curling or opening around joints

• 50% reduction in fork-lift wheel replacement frequency

• 25% improvement in fork-lift productivity due to enhanced speeds

Crack-less

• 100% reduction in crack maintenance costs

• Improved productivity of fork lifts

• Improved aesthetics and work environment

• Reduction in fork-lift wheel replacement frequencySavings in Total Lifecycle Cost of

Ownership

> Rs 2500 Per SqMeter

75% Lower Turnaround Time

• Jointless nature, thin concrete slabs and state-of-the-art equipment combine to deliver 10,000 Sq Meter floor in less than 10 days.

• Early realization of rentals and higher customer satisfaction

Super-Flat Floor

• State-of-the-Art equipment and extensive expertise allow us to deliver super-flat floor, FM-2 as per TR-34.

Smooth Surface

• Advanced and sophisticated fiber blowing machines, S15R laser screed machine, heavy trowels, dry shake hardeners and advanced concrete mix design – all combine to deliver a smooth surface with not even a single fiber popping out

Contents



Method of Execution




Project Overview

• Daimler India Commercial Vehicles Pvt. Ltd.

• Bus Body Assembly Factory:

‒ To manufacture and assemble buses under the Mercedes-Benz and BharatBenz brands.

‒ Only Daimler Truck plant worldwide, that manufactures three brands of Trucks and Buses, as well as engines under one roof.

Client

• Floor Area: 3,325 Sq Meters

• Location: Oragadam Industrial Area, Chennai, IndiaSize and Location

• Floor Execution Dates: 21st, 22nd and 24th of November, 2014

• Contractor: Advanced Construction Technologies Pvt. Ltd. (Chennai) – Licensed contractor of Primekss Germany GmbH

Execution

Scope of Supply: Turn-Key Flooring Solution

• Floor design solution

• Concrete mix design

• Pour plan

• Electronic Quality Management System (PrimeQuality)

• Supervision of Concrete Production

• Proprietary Primekss Admixtures (PrimeDC and PrimeFlow)

• Concrete

• Steel Fibers

• Pre-engineered Day Joints

• Dry-shake hardener

• Cosinus Slide joint from HCJ Belgium

• Deployment of fiber blower machine for dosing steel fibers

• Deployment of dispensers and dosing pumps for dosing admixtures

• Laying the floor using Laser Screed machine

• Deployment of Heavy Ride on Trowels, Bull floats and Bump cutters

Supported by Primekss Labs

Supported by Primekss Project Management Team

Sourced from Primekss Factory in Europe

Sourced from select vendors under stringent QC by Primekss Labs

Deployed by ACT

Contents



Execution




Floor Design and Concrete Design Mix

• Slab Thickness: 100 MM

• Steel Fiber Dosage: 35 KG/CuM

• Steel Fiber Specs: HE 75/50 Hooked End; Tensile Strength > 1200 N/mm3

• Concrete grade: M30

• Distance between day-joints: 60M X 60M (maximum)

• Includes: PrimeTEH shrinkage reducing technology

• Modulus of subgrade reaction k: 0.05 N/mm3

• Single pointload: 10 kN

• Dynamic loads from fork-lift

• Capacity: 5 tons

• Wheel load Q: 17.5 kN/wheel

• Contact pressure p: 2 N/mm2

• UDL: 50 kN/mm2

Design

Solution

• Advanced and customized mix design was specified by

Primekss Labs in Europe, including:

• Water cement ratio

• Cement content

• Aggregate proportioning

• PrimeFlow dosage

• PrimeDC dosage

Concrete Mix

Design

Pour Plan and Cross Section

Pour Plan

• 3325 Sq Meters

• Delivered in 3 day pours

• Day 1: 1065 Sq Meter



Cross Section

• No PCC

• Directly laid on compacted earth

• 100 mm PrimeComposite slab

2015.03.13.

Non-Shrink Concrete

Non-shrink Concrete is achieved with the help of:

• Proprietary and patented Primekss Admixtures

• Advanced and highly sophisticated engineering for concrete design mix

• Special dosing machines for admixtures

• Stringent quality control measures

PrimeDC Pump and Steel fiber dispenser

2015.03.13.

State-of-the-Art Machinery: S15RR Boom Type Laser Screed by Somero Inc (USA)

S-15R Somero Laser Screed and Bump cutter in action

• Lays upto 465 sq meters per hour

• Improved FF & FL numbers

• Improved quality in leveling

• Less dependence on labour

• Ensures fibers are put in place

2015.03.13.

State-of-the-Art Machinery: Heavy Hydraulic 10 Blades ROT from Atlas Copco

Heavy Ride-on-Trowels from Atlas Copco

• Achieves high degree flatness

• Ensures steel fibers are pushed below the top surface and do not stay visible

• Best-in-class finishing for the flooring.

• High finishing capacity.

Advanced Steel Fiber Blower Machine: Imported from Belgium

• Highly sophisticated fiber blowing machine – imported from Europe

• Ensures uniform orientation of steel fibers

• Ensures homogenous distribution of steel fibers

• Ensures no steel fibers pop out of the floor due to right orientation and distribution

• Placing temperatures monitored throughout the pours

2015.03.13.

Best-in-Class Pre-Engineered Joints and Steel Fibers

• Best-in-class pre-engineered joints are imported from Europe and deployed on PrimeComposite floors as construction joints or day-joints

• Ensure smooth movement of fork-lifts on the floor

• Non-shrink concrete ensures Zero Opening around the joints

• Best-in-class loose steel fibers with the following specifications are deployed:

‒ HE 75/50

‒ Hooked ends

‒ Tensile strength > 1200 N/mm3

• Better tensile strength

• Strain-hardening

2015.03.13.

PrimeQuality: Electronic Quality Management Tool

• PrimeQuality is an electronic quality management system.

• It ensures that all PrimeCompositefloors are subject to the same quality control measures and processes that have made Primekss the leading flooring contractor in Europe.

• PrimeQuality system is installed on iPads equipped with protective military case for safe use at the construction site.

• Trained supervisors use these to input information at various stages to ensure consistent quality.

Contents



Method of Execution




Non Shrink Concrete: Concrete That Doesn’t Shrink!

• Non shrink concrete helped achieve zero opening around joints

• No visible cracks across the floor.

• No curling visible.

Jointless Floor – No Saw Cuts, No Expansion Joints

• No Saw Cut Joints - complete elimination of all problems associated with saw cuts such as:

• Poor load transfer

• Curling around joints

• High maintenance costs due to sealants etc.

• No Expansion Joints

• Floor delivered in just three day pours of about 1150 sq meters each separated by day joints.

• Day joint is an imported pre-engineered joint manufactured by Cosinus Slide (Belgium)

Cutting-edge Concrete Recipe: M30 Grade with Minimum Cement Content

• Samples of local cements of 10 different brandsand grades along with local aggregate samplessourced from multiple options were shippedover to Primekss Labs in Riga.

• The team at Primekss Labs, comprising of someof the top concrete engineers in Europe, turnedup with a highly sophisticated and optimizedconcrete mix design, with clearly defined:

• Cement Content (minimized)

• Aggregate proportioning

• w/c ratio

• Primekss admixture dosages

• The strength, slump and setting times achievedwith the mix design provided were substantiallyimproved than what are achieved with localconventional RMC mix designs.

15.19

22.07

28.07

32.3 33.33

42.37

0

5

10

15

20

25

30

35

40

45

50

0

0 5 10 15 20 25 30 35 40 45 50 55 60 65 70

Age (Days)

Cube Strength Result Concrete Strength (N/MM2)

Days 3 7 14 21 28 60

Cube strength in N/mm2 15.19 22.07 28.07 32.3 33.33 42.37

Super Flat Floor Achieved: Spot Levels and Flatness Readings are Proof

Spot Levels and Flatness Measurements recorded within 48 hrs of casting. Summary of Spot Levels

Smooth Surface: Zero Fibers Popping Out

• Not a single fiber popped out of the surfaceeven with such a high dosage of steel fibersused.

• Steel fiber blower imported from Europeensured uniform orientation and homogeneousdistribution of fibers.

• Heavy ride-on-trowels imported from USAensured any fibers that may have come outwere crushed and surface was smooth.

• Application of dry shake hardeners also ensuredsmooth surface and abrasion resistance.

• Sophisticated concrete mix design combinedwith S15R Laser Screed machine finally madesure uniform application of concrete.

Contents



Method of Execution




PrimeComposite will deliver savings > Rs 2500 per sq m over the floor lifecycle

• Quicker turnaround of the floor will allow early delivery of the floor leading to savings on notional rental

as well as allow early commencement of production.

• Savings due to notional rental: Rs 167 per SqM

Opportunity

Cost

Savings

Lifecycle

Savings

Intangible

Benefits

• Over a duration of five years, savings due to improved productivity and reduced maintenance costs will

generate the following savings:

‒ Savings due to lower hard wheel replacements of loaders: Rs 400 per SqM

‒ Savings due to reduction in # of forklifts in operation: Rs 1900 per SqM

‒ Savings in joint and crack repairs: Rs 90 per SqM

• Reduction in down-time due to lower curling

• High residual value of the floor

• Improved aesthetics and better work environment

• Improved fork-lift movements will ensure improved incidents of health hazards for employees

Savings Estimation for Total Lifecycle Cost of Ownership > Rs 2500 per sq m

1 Savings in loss of warehouse rent

Notional rent per unit area 200 Rs per SqM per month

Saving on floor delivery turnaround time 0.8 Months

Savings in loss of rent 167 Rs per SqM

2 Savings in Hard Wheels of Loaders

Reduction in hard-wheel replacements over traditional floors 50%

Replacement cost in traditional floors 13.3 Rs per SqM per Month

Replacement cost in PrimeComposite floors 6.7 Rs per SqM per Month

Savings over 60 months with PrimeComposite 400 Rs per SqM

3 Savings due to Improved Productivity

Reduction in # of Fork Lifts and related manpower under operation 25%

Cost of fork lift rental and manpower in traditional floors 126.7 Rs per SqM per Month

Savings over 60 months with PrimeComposite 1900 Rs per SqM

4 Savings in Joint-Repair

Joint repair cost in traditional floors 1 Rs per SqM per Month

Savings over 60 months 60 Rs per SqM

5 Savings in Crack-Repair

Crack repair cost in traditional floors 0.5 Rs per SqM per Month

Savings over 60 months 30 Rs per SqM

2557 Rs per SqMGross Savings with PrimeComposite Floor

Contents



Method of Execution




The floor will be guaranteed for any defects for a 3-year period

• Broadly, guarantee of the floor for 3 years from hand over will

cover:

‒ Cracks (small opening) on the floor over 0.5mm in width and

over 20mm in depth for a length greater than 300mm.

‒ Abrasion Resistance of the floor shall be less than 3mm /

3000 Meter according Amsler test NBN B 15-223 (1990)

‒ Nett Shrinkage at the Day joint will not be more than 5mm,

after 3 years.

‒ Flatness remains at the same level as the day of the casting of

the slab. Between the day joints there will be no

deformation. Starting point of floor survey should be 300 mm

from the joints. Generally, flatness measurements should be

made within 48 hrs of finishing of the floor.

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PrimeComposite Flooring System · Project Overview • Daimler India Commercial Vehicles Pvt. Ltd....

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